Masakazu Kawahara

Thermal Properties of Diamond-Particle-Dispersed Cu-Matrix-Composites Fabricated by Spark Plasma Sintering (SPS)

Diamond-particle-dispersed copper (Cu) matrix composites were fabricated from Cu-coated diamond particles by spark plasma sintering (SPS) process, and the microstructure and thermal properties of the composites fabricated were examined. These composites can well be consolidated in a temperature range between 973K and 1173K and scanning electron microscopy detects no reaction at the interface between the diamond particle and the Cu matrix. The relative packing density of the diamond-Cu composite increases with increasing sintering temperature and holding time, reaching 99.2% when sintered at a temperature of 1173K for a holding time of 2.1ks. Thermal conductivity of the diamond-Cu composite containing 43.2 vol. % diamond increases with increasing relative packing density, reaching a maximum (654W/mK) at a relative packing density of 99.2%. This thermal conductivity is 83% the theoretical value estimated by Maxwell-Eucken equation. The coefficient of thermal expansion of the composites falls in the upper line of Kerner’s model, indicating strong bonding between the diamond particle and the Cu matrix in the composite.

Synthesis of New Structural and Functional Materials by SPS Processing

Capabilities of synthesizing new structural and functional materials by SPS processing were indicated by exemplifying the synthesis of nano-structured alumina with high bending strength or high transparency, Al/diamond composites with high thermal conductivity and zirconia(3Y)/ SUS410L FGM. In the synthesis of alumina, the bending strength of more than 720MPa was attained by choosing suitable SPS conditions. It was also indicated that SPS processing could easily synthesize Al/diamond composites with high thermal conductivity of more than 400W/(m･K), suggesting elaborate control of interface between Al and diamond in SPS consolidation. Further, zirconia(3Y)/SUS410L FGM could easily be fabricated by SPS. Mechanical weakness in the zirconia(3Y)-rich layers of the FGM was shown from the analysis of stress state based on Raman scattering method. It is suggested that the designing of the layer staking in FGM based on the Raman scattering analysis is effective for the improvement of the weakness in the FGM.

Biodegradable Fiber Reinforced Ti Composite Fabricated by Spark Plasma Sintering Method

Ti and Ti alloys are particularly attractive materials as the metallic implant-material. This is because that these alloys have low shear modulus and the good biological compatibility with bone. However, interfacial adhesion ability of bone and Ti alloy is low. As improvement method of the interfacial adhesion ability, bioaffinity material like hydroxyapatite has been coated on surface of the Ti alloys. However, such bioaffinity materials have low strength and wear resistance. In this study, Ti composites containing biodegradable poly-L-lactic-acid (PLLA) fiber were fabricated by spark plasma sintering (SPS) method. The PLLA fiber plays a role as reinforcement in Ti matrix, and can be gradually decomposed inside body with progress of time. By the decomposition of PLLA, pore is generated in Ti matrix, and bone simultaneously penetrates into the pore. Therefore, tightly bond between bone and Ti matrix can be expected. Using the Ti-PLLA composites fabricated by SPS method, microstructural observation and mechanical tests were performed. It was found that Ti-PLLA composite has laminate-layer structure with plate-like shape PLLA. Hardness and wear behavior of Ti-PLLA composite has anisotropy due to its structure. However, strength of the Ti-PLLA composite is low because of the imperfect sintering of Ti matrix. Since sintering of Ti matrix can be improved by changing the temperature of SPS, Ti-PLLA composite with anisotropic mechanical properties can be expected by SPS method.

HIGH SPEED PROCESSING OF NI-ALUMINIDES-REINFORCED NI-MATRIX COMPOSITES BY PULSED-CURRENT HOT PRESSING (PCHP)

Nickel-aluminides-reinforced nickel-matrix composites were fabricated from 0.05mm-thick nickel foils and 0.012mm-thick aluminum foils, in a process using a pulsed-current hot pressing (PCHP) equipment, and the effect of reaction temperature on mechanical properties of the composites was investigated. The composites were of laminated structure and composed of Ni and reacted layers containing Ni-aluminides. The chemical composition of the reacted layers was dependent on reaction temperature in the temperature range employed. Tensile testing at room temperature revealed that the reaction temperature evidently influences mechanical properties, including tensile strength, elongation and fracture mode, of the composites. The tensile strength and elongation of composites fabricated at 1373K were 500MPa and 3.8%, respectively. Microstructure observations of fractured specimens revealed that Ni layers of the composite played a significant role in prohibiting the growth of numerous cracks emanating from Ni-aluminides. In the case of composites fabricated at 1373K, in addition, crack propagation between Ni-rich Al-solid-solution layers and cellular Ni3Al in the Ni-aluminides were prevented by mutual interaction.

Processing and properties of TiNi shape memory fiber-reinforced 6061 aluminum matrix composite made by spark plasma sintering

Aluminum alloy matrix composite reinforced by continuous TiNi shape memory allow (SMA) fiber was fabricated by Spark Plasma Sintering (SPS) process of A1 alloy powder with 20 vol. % of the TiNi SMA fiber, and its microstructure and mechanical properties were examined. The A1 alloy powder with the TiNi fiber was readily consolidated into composite at temperatures between 633K and 873K. The relative packing density of the composite fabricated increased with increasing sintering temperature. Reaction occurred at the boundary between A1 alloy matrix and TiNi fiber and the interfacial reaction is considered to consist of three intermetallic phases, Ni3Ti (next to TiNI), Ni2Ti and Al3Ni (next to A1 matrix). The tensile yield stress of the composite deformed in tension at 373K was higher by about 40MPa than at 293K.

Thermal Conductivity of Cubic Boron Nitride (cBN) Particle Dispersed Al Matrix Composites Fabricated by SPS

Cubic boron nitride (cBN) particle-dispersed-aluminum (Al) matrix composites were fabricated from the powder mixture composed of cBN, pure Al and Al-5mass% Si alloy in liquid and solid co-existent state by spark plasma sintering (SPS) process. Al/cBN composites were well consolidated by heating at a temperature range between 798 K and 876 K for 1.56 ks by SPS. Microstructures of the composites produced were examined by scanning electron microscopy and the reaction between the cBN particle and the Al matrix was not detected. The relative packing density of the Al/cBN composite was higher than 99 % in a volume fraction range of cBN up to 45 %. The thermal conductivity of the composite increased with increasing the cBN content in the composite in a volume fraction range of cBN between 35 and 45 vol. %. The highest thermal conductivity of 305 W/mK was obtained for Al matrix composite containing 45 vol.% cBN particles.

Densification of Alumina Powder by Using PECS Process with Different Pulse Electric Current Waveforms

Densification and sample temperature of alumina (Al2O3) powder during pulsed electric current sintering with different pulse power generators, inverter type and pulsed direct current type were investigated. The sample temperature for inverter generator was higher than that for pulsed direct current generator in same die temperature ranging form 800 to 1400oC. The relative density increased with increasing of the sample temperature.

Thermal Properties of Al/Diamond Composites Fabricated in Continuous Solid-Liquid Co-Existent State by SPS

Diamond-particle-dispersed-aluminum (Al) matrix composites were fabricated in continuous solid-liquid co-existent state by spark plasma sintering (SPS) process from the mixture of diamond powders, pure Al powders and Al-5mass%Si alloy powders. The microstructures and thermal conductivities of the composites fabricated were examined. These composites were well consolidated by heating at a temperature range between 798K and 876K for 1.56ks during SPS process. No reaction at the interface between the diamond particle and the Al matrix was observed by scanning electron microscopy for the composites fabricated under the sintering conditions employed in the present study. The relative packing density of the diamond-Al composite fabricated was 99% or higher in a volume fraction range of diamond between 45% and 50%. Thermal conductivity of the diamond-Al composite containing 50 vol.% diamond reached 552W/mK, approximately 95% the theoretical thermal conductivity estimated using Maxwell-Eucken’s equation.

Bimodal and Monomodal Diamond Particle Effect on the Thermal Conductivity of Diamond Particle Dispersed Al Matrix Composite Produced by SPS

Diamond-particle-dispersed aluminum (Al) matrix composites consisting of monomodal and bimodal diamond particles were fabricated in spark plasma sintering process, where the mixture of diamond, pure Al and Al-5mass% Si alloy powders were consolidated in liquid and solid co-existent state. Microstructures and thermal properties of the composites fabricated in such a unique way were investigated and the bimodal and monomodal diamond particle effect was evaluated on the thermal properties of the composites. The composites can be well consolidated in a temperature range between 773 K and 878 K and scanning electron microscopy detects no reaction product at the interface between the diamond particle and the Al matrix. Relative packing density of the composite containing monomodal diamond particles decreased from 99.1% to 87.4% with increasing volume fraction of diamond between 50% and 60%, whereas that of the composite containing bimodal diamond particles was higher than 99% in a volume fraction of diamond up to 65%. The thermal conductivity of the composite containing bimodal diamond particles was higher than that of the composite containing monomodal diamond particles in a volume fraction of diamond higher than 60% and the thermal conductivity of the composite containing 70 vol.% bimodal diamond particles was 578 W/mK at R.T..

Properties of Boron Fiber Reinforced Aluminum Matrix Composites Fabricated by Pulsed Current Hot Pressing (PCHP)

Boron-fiber-reinforced Al-matrix composite was fabricated by a pulsed current hot pressing (PCHP) process at a pressure of 32MPa for 600s. It was found that the boron fiber and the Al-matrix were well bonded when the PCHP process was performed at a holding temperature of 773K. No interfacial reaction layer was observed along the interface between the boron fiber and the matrix when PCHP was done at 773K for 600s. Tensile deformation carried out at room temperature for the composite showed that the tensile yield stress increased with increasing volume fraction of the boron fiber in the composite. The composite with 17.2 vol.% of boron fiber presented a tensile yield stress of 600MPa. This value was about 90% the yield stress estimated by a force equilibrium equation of a composite taking into account the direction of fiber axis.